Unitary insulated glass unit and method of manufacture

ABSTRACT

A multi-paned fenestration unit in which the glass panes are manufactured directly into the support structure without first manufacturing an insulated glass unit. The support structure is designed to provide the structural support for the glass panes without a separate spacer.

RELATED APPLICATIONS

[0001] This application is a divisional of application Ser. No.09/365,014, filed Aug. 2, 1999, now U.S. Pat. No. 6,463,706, which is adivisional of application Ser. No. 08/929,885, filed Sep. 15, 1997, nowU.S. Pat. No. 6,055,783, which two applications are hereby incorporatedherein by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention relates generally to a fenestration unit whichdoes not include an insulated glass unit (IGU). More specifically, theglass panes are placed directly into the sash without first beingpermanently fastened to each other by a spacer. This invention alsoincludes a method for manufacturing a fenestration unit without theutilization of an IGU.

[0004] 2. Description of the Prior Art

[0005] Early fenestration units, including windows and doors, only had asingle pane of glass. Typically, the glass would be placed in the sashand then a glazing material would be applied to hold the glass into thesash. However, in more recent times, two or more panes of glass havebeen utilized in windows for better insulating value. A gap between anytwo glass panes creates further insulation. The prior art teaches theuse of a separate spacer between the two glass panes to create such agap and to structurally support the two panes of glass.

[0006]FIG. 1 illustrates a typical IGU 10 of the prior art. A firstglass pane 11 is sealed to one end of spacer 12 with a sealant 14, and asecond glass pane 16 is sealed to the other end of spacer 12 withsealant 14. The spacer 12 can be of many different shapes but often itis made with a jagged edge as shown in FIG. 1 to reduce the conductanceof heat through the spacer. This combination of two or more glass panesseparated by a spacer is manufactured as a unit (IGU 10) and then laterplaced into the sash of the fenestration unit.

[0007]FIG. 2 illustrates the IGU 10 after it has been placed in the sash17 of a fenestration unit.

[0008] The prior art fenestration units have a number of problems.Manufacturing involves two operations in which the first operation ismanufacturing the IGU and the second operation is placing the IGU in thesash. This dual operation process incorporates significant cost into thefenestration unit. Additionally, this dual operation process typicallyinvolves shipping glass from the glass factory to the windowmanufacturer in the form of an IGU. Such shipping involves greater costbecause the IGU's take up more space and they are easier to break thanindividual glass panes. Additionally, despite efforts to minimizethermal conductivity through the spacer 12, there continues to besignificant heat loss through the spacer 12.

SUMMARY OF THE INVENTION

[0009] The invention has as its object manufacturing a fenestration unitin one operation wherein the glass panes are placed directly into thesash without the first operation of manufacturing an IGU. The sash (alsoreferred to as the “support structure”) of the fenestration unit of thisinvention provides all of the structural support for the glass paneswithout the use of an IGU. In other words, the support of the glasspanes is an integral part of the sash.

[0010] The invention provides a method of manufacturing a fenestrationunit including the steps of constructing a support structure including afirst receiving surface and a second receiving surface, placing a vaporbarrier in contact with the first receiving surface and in contact withthe second receiving surface, depositing a first primary sealant on aportion of the vapor barrier in contact with the first receivingsurface, depositing a second primary sealant on a portion of the vaporbarrier in contact with the second receiving surface, placing a firstglass pane onto the first primary sealant on the first receivingsurface, placing a second glass pane onto the second primary sealant onthe second receiving surface, depositing a first secondary sealantbetween the first glass pane and the first receiving surface, where thefirst glass pane is structurally supported by the first receivingsurface, and depositing a second secondary sealant between the secondglass pane and the second receiving surface, where the second glass paneis structurally supported by the second receiving surface.

[0011] The invention also includes a fenestration unit comprising afirst glass pane and a second glass pane. Both glass panes have aninside surface and an outside surface such that the inside surfaces faceeach other. The fenestration unit also includes a support structurehaving a first receiving surface and a second receiving surface. Thefirst receiving surface of the sash receives the inside and outsidesurfaces of the first glass pane and the second receiving surfacereceives the inside and the outside surfaces of the second glass pane.The fenestration unit also includes a vapor barrier placed in contactwith the first receiving surface and the second receiving surface.

[0012] The invention further provides a method of manufacturing afenestration unit including the steps of constructing support structuremembers where each support structure member has a first receivingsurface, a second receiving surface, a first end, and a second end. Themethod also includes the steps of depositing a first secondary sealanton the first receiving surfaces of each of the support structuremembers, depositing a second secondary sealant on the second receivingsurfaces of each of the plurality of support structure members,positioning first and second glass panes on the first and secondreceiving surfaces, respectively, and fastening the ends of the supportstructure members to each other. This method forms a support structurearound the first and second glass panes where the first receivingsurface contacts the inside surface of the first glass pane and thesecond receiving surface contacts the inside surface of the second glasspane.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a cross-sectional view of a prior art IGU.

[0014]FIG. 2 is a cross-sectional view of an IGU of the prior artinserted into a sash.

[0015]FIG. 3 is a frontal view of the fenestration unit of the inventionincluding a partial cut-away.

[0016]FIG. 4 is a cross-sectional view of a first embodiment of theinvention taken along the lines 4-4 of FIG. 3.

[0017]FIG. 5 is a cross sectional view of the anti-outgassing strip ofthe first embodiment.

[0018]FIG. 6 is a cross-sectional view of the first embodiment of theinvention and a window frame in a casement application.

[0019]FIG. 7 is a frontal view of the fenestration unit of a secondembodiment of the invention including a partial cut-away.

[0020]FIG. 8 is a cross-sectional view of the second embodiment of theinvention taken along a line 8-8 of FIG. 3.

[0021]FIG. 9 is a cross-sectional view of the anti-outgassing strip ofthe second embodiment.

[0022]FIG. 10 is a cross-sectional exploded view of a third embodimentof the invention.

[0023]FIG. 11 is a frontal view of the fenestration unit of a fourthembodiment of the invention.

[0024]FIG. 12 is a cross-sectional view of a fourth embodiment of theinvention taken along the line 12-12 of FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] In the following description of the preferred embodiment,reference is made to the accompanying drawings which form a part hereof,and in which is shown by way of illustration specific embodiments inwhich the invention may be practiced. It is to be understood that otherembodiments may be utilized and structural changes may be made withoutdeparting from the scope of the present invention.

[0026]FIG. 3 generally illustrates a fenestration unit 18 of theinvention. The fenestration unit 18 includes a sash 19 which could alsobe a window or door frame. The use of the term “sash” is not intended tobe limited to a strict sense of the word, but instead is defined as anystructure that supports or holds a transparent material such as a glasspane. Therefore, the term “sash” will be used throughout this detaileddescription of the preferred embodiments, but it is understood toinclude a typical sash as well as any suitable support structure. Thesash 19 includes four sash members 19 a, 19 b, 19 c and 19 d and isrectangular in shape. However, the sash members do not have to be linealand the sash 19 could be any shape. Construction of the sash 19 involvesconstructing the sash members 19 a-d and then fastening the sash members19 a-d together to create the sash 19. The sash members 19 a-d can beconstructed by extrusion, wood milling or any other suitablemanufacturing technique. The four sash members 19 a-d can be fastenedtogether in any manner known in the art. For example, depending on thetype of material used for the sash 19, the lineal sash members 19 a-dcould be connected together by an additional piece of connectinghardware, by vibratory welding, by temporary insertion of a heat platebetween two adjacent sash members, or by any other method known in theart.

[0027] The sash 19 supports the first glass pane 20 and second glasspane 21. The first glass pane 20 has an inner portion 22 and a borderportion 23 (as seen through the cutaway portion of the sash 19). Theborder portion 23 is the portion around the periphery of the first glasspane 20, i.e., the portion proximate to the sash 19. In a preferredembodiment, the border portion 23 extends from the side 30 of the firstglass pane 20 to about one inch from the side 30 in the direction of theinterior portion 22 of the first glass pane 20. The inner portion 22 isthe portion of the first glass pane 20 which is not part of the borderportion 23 and which is therefore a further distance from the sash 19.The second glass pane 21 also has an inner portion 24 and a borderportion 25 (also shown in the cut-away portion of the sash 19). Theinner portion 24 and the border portion 25 are defined the same as abovefor the first glass pane 20. The outside surface 26 of the first glasspane 20 faces the outdoors. The outside surface 32 of the second glasspane 21 faces the indoors.

[0028]FIG. 4 is a cross-sectional view of the first embodiment of theinvention taken along the lines 4-4 of FIG. 3. The first glass pane 20includes an outside surface 26, an inside surface 28 and a side 30. Thesecond glass pane 21 includes an outside surface 32, an inside surface34 and a side 36.

[0029] The sash 19 may be made of any low-thermally conducting material.For example, the sash 19 could be hollow vinyl, hollow thermoplastic,thermoset pultrusion, milled solid wood or wood with a vinyl coating.Alternatively, the sash could be made of Fibrex™ material which is awood fiber and polyvinyl chloride(PVC) composite patented by AndersenCorporation (See U.S. Pat. Nos. 5,406,768; 5,497,594; 5,441,801;5,518,677; 5,486,553; 5,539,027).

[0030] The sash 19 includes a first receiving surface 38, a secondreceiving surface 40 and an interior surface 42. An anti-outgassingstrip 44 has a first leg 47 at one end of the anti-outgassing strip 44and a second leg 49 at the opposite end and an interior portion 53. Theinterior portion 53 is located between the first leg 47 and the secondleg 49. The first leg 47 is attached to the first receiving surface 38,the second leg 49 is attached to the second receiving surface 40 and theinterior portion 53 of the anti-outgassing strip 44 is attached to theinterior surface 42 of the sash 19. The strip 44 is illustrated in FIGS.4 and 5. The anti-outgassing strip 44 prevents gas particles in the sash19 from outgassing into the space 45 between the first glass pane 20 andthe second glass pane 21, where these particles could interfere with theclarity of the fenestration unit 18. The anti-outgassing strip 44 is athin foil of metal but could be any material that prevents the gasparticles from the sash 19 from passing through to the space 45. Forexample, the anti-outgassing strip 44 may be made of stainless steel oraluminum. The anti-outgassing strip 44 is preferably made as thin aspossible to reduce the conduction of heat through the strip 44 and yetthick enough to prevent outgassing. A stainless steel anti-outgassingstrip 44 must be at least about 0.001″ (inches) thick in order toeffectively reduce the movement of gas particles from the sash 19 to thespace 45. It is sometimes desired to use an anti-outgassing strip 44that is between about 0.003″ (inches) and 0.005″ (inches) because such athickness is easier to apply to the sash 19 without tearing ordestroying the anti-outgassing strip 44. It is also within the scope ofthis invention to apply a metallic spray to the interior surface 42, thefirst receiving surface 38 and the second receiving surface 40. Thismetallic spray would then be an anti-outgassing strip. Theanti-outgassing strip 44 may be affixed to the sash 19 by an adhesive.Alternatively, the anti-outgassing strip 44 may include barbs 43, asshown in FIGS. 4 and 5, which are pressed into the sash and which holdthe anti-outgassing strip 44 to the sash 19. It is also within the scopeof this invention to merely place an anti-outgassing strip, withoutbarbs and without an adhesive, on the interior surface 42, the firstreceiving surface 38 and the second receiving surface 40. Then thesealants and glass panes are placed as shown in FIG. 4 and describedbelow to permanently hold the strip 44 in place.

[0031] The various sealants and their functions will now be described.The portion of the outside surface 26 of the border portion 23 of thefirst glass pane 20 that is not situated over the anti-outgassing strip44 is attached to the first receiving surface 38 by a first secondarysealant 46. The function of the first secondary sealant 46 is to providean adhesive bond between the first glass pane 20 and the sash 19. Thisadhesive bond is structural and prevents the first glass pane 20 frombreaking away from the sash 19 in strong winds. The first secondarysealant 46 also prevents water from flowing along the outside surface 26of the first glass pane 20 and into the space 45. GE 2512 by GeneralElectric Company is used as first secondary sealant 46 but otheradhesives known in the art for attaching glass to the sash material mayalso be used. The portion of the outside surface 26 of the borderportion 23 that is situated over the anti-outgassing strip 44 isattached to the anti-outgassing strip 44 by a first primary sealant 48.The function of the first primary sealant 48 is to prevent migration ofair or argon or any other insulating gas from the space 45 to the worldoutside the space 45. The first primary sealant 48 could be any compoundthat prevents such migration such as, for example, polyisobutylene. Thefunction of the sealant 48 is to prevent gas molecules from movingeither into the space 45 or from leaving the space 45. It is within thescope of this invention to use one adhesive/sealant in place of firstsecondary sealant 46 and first primary sealant 48. The single adhesivewould perform a dual function of structurally supporting the glass panesand sealing the space 45.

[0032] The portion of the inside surface 34 of the border portion 25 ofthe second glass pane 21 that is not situated over the anti-outgassingstrip 44 is attached to the second receiving surface 40 by a secondsecondary sealant 50 which is the same as and performs substantially thesame function as the first secondary sealant 46. The portion of theinside surface 32 of the border portion 25 of the second glass pane 21that is situated over the anti-outgassing strip 44 is attached to theanti-outgassing strip 44 by a second primary sealant 52. The secondprimary sealant 52 is the same as and performs substantially the samefunction as the first primary sealant 48.

[0033] The depositing of the secondary sealants 46 and 50 and theprimary sealants 48 and 52 may be accomplished by hand or using amachine. For example, a caulk gun could be used to deposit the varioussealants. Robotic machines are also known in the art for depositingsealants in a specified pattern.

[0034] The first receiving surface 38 may include a lip 54 which is aportion that is raised from the remainder of the first receiving surface38. The lip 54 provides a space between the first glass pane 20 and thefirst receiving surface 38 such that the first secondary sealant 46 andthe first primary sealant 48 are not squeezed out from between the firstglass pane 20 and the first receiving surface 38, thereby preventing amessy appearance along the interface between the sash 19 and the innerportion 22 of the outside surface 26 of the first glass pane 20.

[0035] The sash shown in FIG. 4 defines hollowed portions 56 which allowfor a lighter weight sash 19 while retaining structural integrity andexcellent insulating properties. However, the invention is not limitedto this configuration. A sash defining more or fewer hollowed portionsor no hollowed portions or differently shaped hollowed portions wouldalso be within the scope of the invention. For example, if the sash 19was made of milled wood, then it would not include the hollowed portions56.

[0036] The sash 19 includes a flange 58 adjacent to the side 36 of thesecond glass pane 21. The flange 58 provides guidance to the properplacement of the second glass pane 21. There is a gap 57 between the end36 of the second glass pane 21 and the flange 58. The purpose of the gap57 is to allow the thermal expansion and contraction of the second glasspane 21 and to allow for permanent shrinkage of the sash 19.

[0037] The second receiving surface 40 includes a stop 41 which is aportion of the sash which is raised. The stop 41 creates a gap betweenthe second glass pane 21 and the second receiving surface 40 such thatthe second secondary sealant 50 and the second primary sealant 52 canremain in that gap. The stop 41 is located at the end of theanti-outgassing strip 44 and the stop 41 therefore forms the juncturebetween the second secondary sealant 50 and the second primary sealant52

[0038] A desiccant material 60 may be attached to the anti-outgassingstrip 44 by an adhesive. In the preferred embodiment, the dessicant 60is an extruded, hot melt adhesive. The desiccant material 60 assists inthe removal of moisture from the space 45. The dessicant material 60could alternatively be an adhesive type dessicant as described in U.S.Pat. Nos. 5,510,416; 5,509,984; and 5,503,884 owned by H. B. FullerLicensing & Financing, Inc.

[0039] The space 45 contains a thermally insulating gas. For example,air, Argon or Krypton or some combination of these three gases could beused. If air is used, then the manufacture of the fenestration unit 18is simplified, because the dessicant 60 will remove moisture from thespace 45 and no steps are necessary to remove the air and replace itwith another gas. The description below discusses filling the space 45with Argon as an example. The description also applies to other gasesthat may be used.

[0040] Filling the space 45 with Argon involves the following steps.First, the sash 19 is constructed with a hole or multiple holes thatconnect the space 45 to the outside air. An example hole is shown ashole 61. A hose can be inserted into this hole and the air sucked out ofthe space 45 through the hose. Then Argon can be inserted into the space45 through the same hose that passes through hole 61. Alternatively, oneor more holes 61 may be used to remove the air while Argon is insertedinto the space 45 through one or more other holes also similar to hole61. Other methods of inserting Argon into the space 45 may be used. Oncethe space 45 is filled with Argon, then the plug 59, shown in explodedview for clarity, is inserted in the hole 61 to seal the space 45. Therecould be multiple holes 61 and plugs 59 per sash 19. The plug 59 can bemaintained in the hole 61 by any method including a friction fit or useof an adhesive.

[0041] The second secondary sealant 50 and the second primary sealant 52may be visible through the second glass pane 21. Therefore, it may bedesirable to place a decorative trim piece along the border portion ofthe second glass pane 21 to hide the sealants from view.

[0042] The manufacture of the embodiment shown in FIG. 4 will now bedescribed. First, the sash 19 including the first receiving surface 38and the second receiving surface 40 is constructed. The construction ofthe sash 19 includes joining the members 19 a-d. Next, theanti-outgassing strip is placed on the interior surface 42, a portion ofthe first receiving surface 38 and a portion of the second receivingsurface 40. As discussed above, the anti-outgassing strip 44 may beattached to the sash 19 by barbs or by an adhesive. A dessicant asdescribed above is then attached to the portion of the anti-outgassingstrip 44 that is adjacent to the interior surface 42 of the sash 19. Thefirst secondary sealant 46 is deposited on the portion of the firstreceiving surface 38 that is not in contact with the anti-outgassingstrip 44. The second secondary sealant 50 is deposited on the portion ofthe second receiving surface 40 that is not in contact with theanti-outgassing strip 44. Next, the first primary sealant 48 isdeposited on the first leg 47 of the anti-outgassing strip 44. Thesecond primary sealant 52 is deposited on the second leg 49 of theanti-outgassing strip 44. The next step is to place the border portion23 of the outside surface 26 of the first glass pane 20 onto the firstreceiving surface 38 such that the border portion 23 of the outsidesurface 26 of the first glass pane 20 sits on the first secondarysealant 46 and the first primary sealant 48. There should be a gapbetween the end 30 and the interior surface 42 of the sash 19. Next, theborder portion 25 of the inside surface 34 of the second glass pane 21is placed on the second receiving surface 40 such that the borderportion 25 of the inside surface 34 of the second glass pane 21 sits onthe second secondary sealant 50 and the second primary sealant 52. Thereshould be a gap 57 between the end 36 and the flange 58. Finally, thespace 45 is filled with a thermally insulating gas through the hole 61as described above.

[0043]FIG. 6 is similar to FIG. 4 with the addition of a frame 62 thatwould be used for a casement window. The outside surface 26 of the firstglass pane 20 faces the outdoors. The outside surface 32 of the secondglass pane 21 faces the indoors.

[0044] In FIG. 6, the plug 59 is shown inserted into the sash assembly.A flexible bulbed weatherstop 63 is attached to the frame 62. When thecasement window is in a closed position as shown in FIG. 6, the flexiblebulbed weatherstop 63 is in contact with the outside surface 32 of thesecond glass pane 21. The sash 19 may be rotated outward away from theframe 62 as is typical of a casement window. In such a case, the outsidesurface 32 of the second glass pane 21 moves away from the flexiblebulbed weatherstop 63. The purpose of the flexible bulbed weatherstop 63is to seal the window to prevent water from traveling between the frame62 and the sash 19 when the window is in its closed position.

[0045] The manufacture of the structure shown in FIG. 6 is the same asfor the structure shown in FIG. 4 with the additional step of placingthe flexible bulbed weatherstop 63 into a groove 77 in the frame 62. Theweatherstop 63 is friction fit into the groove 77 so that theweatherstop 63 will not fall out of the groove 77. Alternatively, anadhesive could be placed in the groove 77 to more securely fasten theweatherstop 63 in the groove. The groove 77 is located such thatweatherstop 63 is adjacent the second glass pane 21 when the window isin the closed position as shown in FIG. 6.

[0046] A frontal view of the second embodiment of the invention is shownin FIG. 7. The sash 76 is made of four sash members 76 a-d. Each sashmember has two ends, for example end 100 and end 102 of sash member 76a. The first glass pane 64 has an inner portion 65 and a border portion67. The second glass pane 70 has an inner portion 71 and a borderportion 73. The inner and border portions in this embodiment are definedthe same as with respect to the previous embodiment described above.

[0047]FIG. 8 is a cross-sectional view taken along the lines 8-8 in FIG.7. Again, in this embodiment as in the first embodiment discussed above,there is not a separate spacer between the two panes of glass and theglass panes are structurally supported entirely by the sash 76.

[0048] The first glass pane 64 has an inside surface 66, an outsidesurface 68 and a side 69. The second glass pane 70 has an outsidesurface 72, an inside surface 74 and a side 75. The inside surface 66 ofthe first glass pane 64 faces the inside surface 74 of the second glasspane 70.

[0049] The sash 76 includes a channel having a U-shaped cross-sectionand a plurality of receiving surfaces 78 that receive the border portion67 of the inside surface 66 of the first glass pane 64, and the borderportion 67 of the outside surface 68 of the first glass pane 64. Thechannel's receiving surface 78 may also abut against the side 69 of thefirst glass pane 64.

[0050] Moreover, the sash 76 includes a second channel having receivingsurfaces 80 that receive the border portion 73 of the inside surface 74of the second glass pane 70, and the border portion 73 of the outsidesurface 72 of the second glass pane 70. The second channel's receivingsurface 80 may also abut against the side 75 of the second glass pane70.

[0051] The sash 76 also includes an interior surface 81 which extendsbetween the first and second channels. In this embodiment, theanti-outgassing strip 82 has a U-shaped cross-section, with an interiorportion extending between a first leg 97 and a second leg 98. Thecentral portion of the anti-outgassing strip 82 extends across thesash's interior surface 81. Each leg of the strip 82 abuts against thefirst receiving surface 78 into the second receiving surface 80. Theanti-outgassing strip 82 is made of the same material and performs thesame function as the anti-outgassing strip 44 of the first embodimentshown in FIG. 4. The anti-outgassing strip 82 may be attached to thesash 76 by an adhesive or by barbs 79. FIG. 9 shows a cross section ofthe anti-outgassing strip 82 including barbs 79 which are inserted intothe sash 76.

[0052] The first receiving surface 78 is attached to the border portion67 of the outside surface 68 of the first glass pane 64 by a adhesive84. The second receiving surface 80 is attached to the border portion 73of the outside surface 72 of the second glass pane 70 by a adhesive 85.The adhesives 84 and 85 are the same and perform the same function asthe adhesives 46 and 50 of the first embodiment.

[0053] The anti-outgassing strip 82 is attached to the border portion 67of the inside surface 66 of the first glass pane 62 by a sealant 86. Theanti-outgassing strip 82 is attached to the border portion 73 of theinside surface 74 of the second glass pane 70 by a sealant 88. Thesealants 86 and 88 are the same and perform the same function as thesealants 48 and 52 of the first embodiment.

[0054]FIG. 8 also shows the desiccant material 90 attached to theanti-outgassing strip 82 along the interior surface 81 of the sash 76.The purpose and design of the desiccant material 90 is the same as thepurpose and design of the desiccant material 60 in the first embodimentof the invention. A dessicant adhesive as described above with respectto the first embodiment may also be used for this embodiment.

[0055] Again, with this embodiment as in the first embodiment, eitherair or Argon or a combination of both may be used to fill the space 92between the first glass pane 64 and the second glass pane 70. If Argonis used, then a hole 94 may be used to insert a hose for removing airand inserting Argon into the space 92. Once the space 92 is filled orpartially filled with Argon, then it may be blocked with a plug 96 whichis shown in exploded view for clarity.

[0056] The manufacture of the second embodiment involves the followingsteps. First, the sash members 76 a-d are constructed. The sash memberscan be made from an extruded vinyl or composite or other material, orthey can be milled from a wood. Second, the anti-outgassing strip 82 isplaced on the interior surface 81 of the sash members 76 a-d. Theplacement of the anti-outgassing strip 82 can either utilize an adhesiveor barbs or both. In a preferred embodiment the anti-outgassing strip 82has a first leg 97, a second leg 98 and an interior portion 99, whereinthe interior portion 99 is between the first leg 97 and the second leg98. The first leg 97 is adjacent to a portion of the first receivingsurface 78, the second leg is adjacent to a portion of the secondreceiving surface 80 and the interior surface 99 of the anti-outgassingstrip 82 is adjacent to the interior surface 81 of the sash 76.

[0057] The first secondary sealant 84 is deposited on the portion of thefirst receiving surface that is not in contact with the anti-outgassingstrip 82. The first primary sealant 86 is deposited on the first leg 97of the anti-outgassing strip 82. The second secondary sealant 85 isdeposited on the portion of the second receiving surface 80 that is notin contact with the anti-outgassing strip 82. The second primary sealant88 is deposited on the second leg 98 of the anti-outgassing strip 82.The depositions can be done manually using a caulk gun or automaticallywith a machine or robot. Then the first glass pane 64 is placed on aplatform or support and the second glass pane 70 is suspended paralleland above the first glass pane 64 with the space between the two glasspanes being similar or equal to the space 92 desired in the ultimatefenestration unit. For example, suction cups could be applied to theoutside surface 72 of the second glass pane 70 to suspend the secondglass pane 70 over the first glass pane 64. The sash members 76 a-d arethen placed around the first and second glass panes 64, 70 such that thefirst receiving surface 78 receives the border portion of the firstglass pane 64 and the second receiving surface 80 receives the borderportion of the second glass pane 70. The ends of the sash members 76 a-dare then fastened together using heat plates or vibratory welding or anyother means of fastening the ends of sash members 76 a-d together toform a sash 76. The resulting sash 76 as shown is rectangular in shape,but it could be any shape.

[0058] A third embodiment of the invention is shown in exploded view inFIG. 10. This embodiment is similar to the second embodiment shown inFIG. 8 with the difference being that the sash in the third embodimentis three sash sections 110, 112 and 114. When the parts are assembledtogether the first receiving surface 120 of the first sash section 110is adjacent to the outside surface 68 and a portion of the end 69. Thesecond receiving surface 122 of the second sash section 112 is adjacentto the inside surface 66 and a portion of the end 69. The thirdreceiving surface 124 located on the second sash section 112 is adjacentto the inside surface 74 and a portion of the end 75. The fourthreceiving surface 126 of the third sash section 114 is adjacent to aportion of the end 75 and the outside surface 72.

[0059] If the sash is rectangular, then there are four first sashsections, four second sash sections and four third sash sections. Theadvantage of using first, second and third sash sections 110, 112 and114 is that manufacturing is accomplished in a bed formation in whichone layer is placed on top of the other. The manufacturing steps aredescribed below.

[0060] First, the three sash sections 110, 112 and 114 are assembled.For a rectangular window, this assembly comprises connecting the fourfirst sash section lineals to each other at the comers to form arectangular frame. The connection can be by any of the methods describedabove including hot plate welding, vibratory welding or the use of amechanical fastener. This rectangular frame is referred to in whole asthe first sash section 110. The same assembly process is performed toassemble the second and third sash sections 112 and 114. Next, theanti-outgassing strip 82 is placed on the interior surface 81, on thesecond receiving surface 122 and on the third receiving surface 124.Then the dessicant material 90 is placed on the interior surface 81 ofthe second sash section 112.

[0061] A first secondary sealant 84 is deposited on the first receivingsurface 120. Alternatively, the first secondary sealant 84 can bedeposited on the border portion 67 of the outside surface 68 of thefirst glass pane 64. Then the border portion 67 of the outside surface68 of the first glass pane 64 is placed on the first receiving surface120. A first primary sealant 86 is deposited on the portion of theanti-outgassing strip 82 that is adjacent to the second receivingsurface 122. Alternatively, the first primary sealant 86 can bedeposited on the border portion 73 of the inside surface 66 of the firstglass pane 64. Next, the second sash section 112 is lowered onto thefirst sash section such that the portion of the anti-outgassing strip 82that is adjacent to the second receiving surface 122 is placed on theborder portion 73 of the inside surface 66 of the first glass pane 64. Asecond primary sealant 88 is deposited on the portion of theanti-outgassing strip 82 that is adjacent to the third receiving surface124. Alternatively, the second primary sealant 88 may be deposited onthe border portion 73 of the inside surface 74 of the second glass pane70. Then the border portion 73 of the inside surface 74 is placed on theportion of the anti-outgassing strip 82 adjacent to the third receivingsurface 124. A second secondary sealant 85 is deposited on the fourthreceiving surface 126. Alternatively, the second secondary sealant 85may be deposited on the border portion 73 of the outside surface 72. Thefourth receiving surface 126 is then placed on the border portion 73 ofthe outside surface 72.

[0062] The three sash sections 110, 112 and 114 may be connectedtogether by any method including by an adhesive such as silicone sealantor by use of a fastener. FIG. 10 shows a screw 130 which fits into thehole 132 which extends through the third and second sash sections 114and 112 and partially into the first sash section 110. A number of suchscrews 130 would be inserted into a corresponding number of holes 132around the entire sash to connect all three sash sections together. Theend result is that the three sash sections 110, 112 and 114 areconnected to form one sash which supports the glass panes.

[0063] A fourth embodiment of the invention is shown in FIGS. 11-12.FIG. 11 generally illustrates a fenestration unit 170 of the invention.The fenestration unit 170 includes a sash 200 which could also be awindow or door frame. The sash 200 includes four sash members 200 a, 200b, 200 c and 200 d and is rectangular in shape. However, the sashmembers do not have to be lineal and the sash 200 could be any shape.Construction of the sash 200 involves constructing the sash members 200a-d and then fastening the sash members 200 a-d together to create thesash 200. The sash members 200 a-d can be constructed by extrusion, woodmilling or any other suitable manufacturing technique. The four sashmembers 200 a-d can be fastened together in any manner known in the art.For example, depending on the type of material used for the sash 200,the lineal sash members 200 a-d could be connected together by anadditional piece of connecting hardware, by vibratory welding, bytemporary insertion of a heat plate between two adjacent sash members,or by any other method known in the art.

[0064] The sash 200 supports the first glass pane 222 and second glasspane 230 creating a space 181 between the glass panes. The first glasspane 222 has an inner portion 172 and a border portion 174. The innerportion 172 and the border portion 174 are defined the same as for theprior embodiments. In a preferred embodiment, the border portion 174(seen through the cut-away of the upper glazing bead 175) extends fromthe side 176 of the first glass pane 222 to about one inch from the side176 in the direction of the inner portion 172 of the first glass pane222. The second glass pane 230 also has an inner portion 178 and aborder portion 180. The inner portion 178 and the border portion 180 aredefined the same as above for the first glass pane 222.

[0065]FIG. 12 shows a cross sectional view of the fourth embodiment ofthe invention. The sash 200 is the same material and is constructed inthe same manner as the sash 19 described above. The sash 200 has ahollowed portion 182. This hollowed portion is to reduce the weight ofthe fenestration unit 170. However, the invention is not limited to theparticular shape of the hollowed portion 182 shown in FIG. 12 and infact it is within the scope of this invention to use a solid sash 200without a hollow portion 182. The sash includes a first receivingsurface 202 which is generally flat but including a stop 204 which isportion of the first receiving surface that is raised above thegenerally flat portion of the first receiving surface 202. The sash 200also includes a second receiving surface 206 which is generally flat butincludes a stop 208. The sash 200 also includes an interior surface 210which is located between the first receiving surface 202 and the secondreceiving surface 206.

[0066] An anti-outgassing strip 212 which is the same as theanti-outgassing strip 82 is located in contact with the interior surface210. The anti-outgassing strip includes barbs 213 for attaching to thesash 200. However, as described above, the invention is not limited tothe use of barbs for attachment to the sash 200. The anti-outgassingstrip 212 includes a first leg 214, a second leg 216 and an interiorportion 218. The first leg 214 is in contact with a portion of the firstreceiving surface 202 as shown in FIG. 12. The second leg 216 is incontact with a portion of the second receiving surface 206 also as shownin FIG. 12. The first leg 214 and the second leg 216 extend up to therespective stops 204 and 208. The interior portion 218 is in contactwith the interior surface 210 of the sash 200. The purpose of thisanti-outgassing strip 212 is the same as for the first two embodimentsof this invention.

[0067] A dessicant material 184 is located on the interior surface 218of the anti-outgassing strip 212. A plug 186 is shown exploded out fromthe hole 188. The plug 186 fits into the hole 188 and serves the samepurpose as the plugs and holes in the earlier described embodiments.

[0068] A first secondary sealant 220 is located between the insidesurface 221 of the first glass pane 222 and the first receiving surface202. The first secondary sealant 220 is the same as the first secondarysealant discussed above with respect to the first two embodiments ofthis invention. A first primary sealant 224 is located between the firstleg 214 of the anti-outgassing strip 212 and the first glass pane 222.The first primary sealant 224 is the same as the first primary sealantsin the first two embodiments of this invention.

[0069] A second secondary sealant 226 is located between the insidesurface 228 of the second glass pane 230 and the second receivingsurface 206. The second secondary sealant 226 is the same as the firstsecondary sealant 220. A second primary sealant 232 is located betweenthe second leg 216 of the anti-outgassing strip 212 and the second glasspane 230. The second primary sealant 232 is the same as the firstprimary sealant 224. The stops 204 and 208 serve the same function asthe stop 41 in the first embodiment.

[0070] The upper glazing bead 175 is an aesthetic piece which hides thesecond secondary sealant 226 and the second primary sealant 232 fromview of an observer. Likewise, the lower glazing bead 177 hides thefirst secondary sealant 220 and the first primary sealant 224 from viewof an observer. The tips 190 and 192 of the glazing beads 177 and 175are flexible so that the tips can be pressed tightly against the outsidesurfaces of the glass panes. The glazing beads 177 and 175 may alsoapply some pressure to the outside surfaces of the first and secondglass panes 222 and 230 respectively. This pressure may assist inholding the glass panes in place while the sealants 220, 224, 226 and232 are curing.

[0071] The manufacturing steps in this fourth embodiment are the same asfor the first embodiment with one exception. The first glass pane ispositioned on the sash 200 differently in that the border portion 174 ofthe inside surface 221 of the first glass pane 222 is placed on thefirst receiving surface 202. The first glass pane 222 may be placed on asupport structure to hold the first glass pane in contact with thesealants and the first receiving surface. Such a support could be atable or other structure. Alternatively, a fast curing sealant or hotmelt can be used as the first secondary sealant 220 to allow the firstglass pane 222 to be quickly adhered to the first receiving surface 202.

[0072] The foregoing description of the preferred embodiment of theinvention has been presented for the purposes of illustration anddescription. It is not intended to be exhaustive or to limit theinvention to the precise form disclosed. Many modifications andvariations are possible in light of the above teaching. It is intendedthat the scope of the invention be limited not by this detaileddescription, but rather by the claims appended hereto.

We claim:
 1. A fenestration unit comprising: a first glass pane havingan inside surface and an outside surface, the inside surface having aborder portion and an inner portion and the outside surface having aborder portion and an inner portion; a second glass pane having aninside surface and an outside surface, the outside surface having aborder portion and an inner portion, and the inside surface having aborder portion and an inner portion, and the inside surface of the firstglass pane facing the inside surface of the second glass pane; and asupport structure comprising: a first receiving surface for receivingthe border portion of the inside surface of the first glass pane and theborder portion of the outside surface of the first glass pane; a secondreceiving surface for receiving the border portion of the outsidesurface of the second glass pane and the border portion of the insidesurface of the second glass pane; and a vapor barrier placed in contactwith the first receiving surface and the second receiving surface. 2.The fenestration unit of claim 1 wherein the support structure furthercomprises an interior surface, between the first receiving surface andthe second receiving surface, wherein there is a space between the firstglass pane and the second glass pane, and the fenestration unit furthercomprises a vapor barrier located adjacent to the interior surface ofthe support structure to prevent outgassing from the support structureinto the space.
 3. The fenestration unit of claim 2 wherein the vaporbarrier is attached to the interior surface of the support structure byan adhesive.
 4. The fenestration unit of claim 2 where the vapor barriercomprises stainless steel.
 5. The fenestration unit of claim 2 whereinthe vapor barrier comprises aluminum.
 6. The fenestration unit of claim2 wherein the vapor barrier is a coating that is sprayed onto theinterior surface of the sash.
 7. The fenestration unit of claim 2wherein the vapor barrier is plastic.
 8. The fenestration unit of claim2 wherein the vapor barrier is ceramic.
 9. The fenestration unit ofclaim 8 wherein the vapor barrier is in adhesive contact with the firstreceiving surface and the second receiving surface.
 10. A method ofmanufacturing a fenestration unit, the fenestration unit including afirst glass pane and a second glass pane each comprising an insidesurface, an outside surface and an edge; each of the inside surfaceshaving a border portion and an inner portion and each of the outsidesurfaces having a border portion and an inner portion, the methodcomprising: constructing a support structure including a first receivingsurface and a second receiving surface; placing a vapor barrier incontact with the first receiving surface and in contact with the secondreceiving surface; depositing a first primary sealant on at least aportion of the vapor barrier in contact with the first receivingsurface; depositing a second primary sealant on at least a portion ofthe vapor barrier in the contact with the second receiving surface;placing a first glass pane onto the first primary sealant on the firstreceiving surface; placing a second glass pane onto the second primarysealant on the second receiving surface; depositing a first secondarysealant between the border portion of the outside surface of the firstglass pane and the first receiving surface, wherein the first glass paneis structurally supported in its entirety by the first receivingsurface; and depositing a second secondary sealant between the borderportion of the outside surface of the second glass pane and the secondreceiving surface wherein the second glass pane is structurallysupported in its entirety by the second receiving surface.
 11. A methodof manufacturing a fenestration unit, the fenestration unit including afirst glass pane and a second glass pane each comprising an insidesurface, an outside surface and an edge; each of the inside surfaceshaving a border portion and an inner portion and each of the outsidesurfaces having a border portion and an inner portion, the methodcomprising: constructing a plurality of support structure members, eachsupport structure member having a first receiving surface, a secondreceiving surface, a first end, and a second end; depositing a firstsecondary sealant on the first receiving surfaces of each of theplurality of support structure members; depositing a second secondarysealant on the second receiving surfaces of each of the plurality ofsupport structure members; positioning the first and second glass paneson the first and second receiving surfaces respectively; and fasteningeach end of each of the plurality of support structure members toexactly one end of a different one of the plurality of support structuremembers such that the plurality of support structure members form asupport structure around the first glass pane and the second glass pane,the first receiving surface contacting the border portion of the insidesurface of the first glass pane, and the second receiving surfacecontacting the border portion of the inside surface of the second glasspane, wherein the first and second glass panes are supported by thesupport structure.